EP1245311B1 - Method and apparatus for production of platelike metal material - Google Patents
Method and apparatus for production of platelike metal material Download PDFInfo
- Publication number
- EP1245311B1 EP1245311B1 EP02252063A EP02252063A EP1245311B1 EP 1245311 B1 EP1245311 B1 EP 1245311B1 EP 02252063 A EP02252063 A EP 02252063A EP 02252063 A EP02252063 A EP 02252063A EP 1245311 B1 EP1245311 B1 EP 1245311B1
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- EP
- European Patent Office
- Prior art keywords
- metal
- platelike
- metal material
- slurry
- continuous
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 239000007769 metal material Substances 0.000 title claims description 60
- 238000000034 method Methods 0.000 title claims description 30
- 238000004519 manufacturing process Methods 0.000 title claims description 21
- 229910052751 metal Inorganic materials 0.000 claims description 91
- 239000002184 metal Substances 0.000 claims description 91
- 239000002002 slurry Substances 0.000 claims description 53
- 238000001816 cooling Methods 0.000 claims description 48
- 239000013078 crystal Substances 0.000 claims description 32
- 238000005520 cutting process Methods 0.000 claims description 17
- 238000002844 melting Methods 0.000 claims description 17
- 230000008018 melting Effects 0.000 claims description 17
- 238000004804 winding Methods 0.000 claims description 17
- 239000000463 material Substances 0.000 claims description 11
- 239000007791 liquid phase Substances 0.000 claims description 7
- 238000005096 rolling process Methods 0.000 claims description 7
- 238000007599 discharging Methods 0.000 claims description 6
- 239000012809 cooling fluid Substances 0.000 claims description 4
- 238000005266 casting Methods 0.000 description 14
- 229910000861 Mg alloy Inorganic materials 0.000 description 10
- 239000002994 raw material Substances 0.000 description 7
- 238000010079 rubber tapping Methods 0.000 description 7
- 238000010586 diagram Methods 0.000 description 6
- 239000007787 solid Substances 0.000 description 6
- 230000015572 biosynthetic process Effects 0.000 description 5
- 238000001746 injection moulding Methods 0.000 description 4
- 238000010118 rheocasting Methods 0.000 description 4
- 239000007790 solid phase Substances 0.000 description 4
- 238000010276 construction Methods 0.000 description 3
- 239000000498 cooling water Substances 0.000 description 3
- 238000004512 die casting Methods 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- 238000010117 thixocasting Methods 0.000 description 3
- 230000001747 exhibiting effect Effects 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- 230000001105 regulatory effect Effects 0.000 description 2
- 238000011282 treatment Methods 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 230000001276 controlling effect Effects 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 229910001338 liquidmetal Inorganic materials 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000009877 rendering Methods 0.000 description 1
- 230000000754 repressing effect Effects 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 238000010008 shearing Methods 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 238000010119 thixomolding Methods 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/06—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars
- B22D11/0622—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars formed by two casting wheels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/10—Supplying or treating molten metal
- B22D11/11—Treating the molten metal
- B22D11/112—Treating the molten metal by accelerated cooling
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00
Definitions
- This invention relates to a method and apparatus for the production of a platelike metal material by effective utilization of the thixotropy inherent in a semiliquid/semisolid metal.
- the thixo-casting method (semiliquid casting method) and rheocasting method (semisolid casting method) have been known as casting methods utilizing the thixotropy inherent in a semiliquid/semisolid metal, namely the property of exhibiting small viscosity and excelling in fluidity.
- These casting methods invariably consist in casting a metal slurry in such a semiliquid/semisolid state formed of an interfused mixture of a liquid-phase metal and a solid-phase metal.
- the thixo-casting method is so adapted as to comprise the steps of heating a solid metal till formation of a metal slurry in the semiliquid state and supplying the formed metal slurry to a metallic mold.
- the rheocasting method is so adapted as to comprise the steps of provisionally melting a solid metal, cooling the resultant molten metal till formation of a metal slurry in the semisolid state containing granular crystals, and subsequently supplying the metal slurry to a metallic mold.
- these casting methods are capable of casting a metal having a high solid-phase ratio and exhibiting low viscosity, they are at an advantage in improving the metallic mold in filling capacity, thereby enhancing the yield of casting, enabling formation of a product of a large size, repressing occurrence of a shrinkage cavity, thereby adding to the mechanical strength of the product, and permitting a reduction in the wall thickness of the product.
- the semiliquid/semisolid metal should contain non-dendritic crystals, preferably spherical crystals, as fine and uniform as permissible.
- the thixo-molding method therefore, generally resorts to a procedure of utilizing a screw-type extruding device popularly used in an injection molding machine and sequentially heating a given solid metal within the barrel of the extruding device while exerting a shearing force thereon till conversion of the solid metal into a metal slurry in a semiliquid state.
- the rheocasting method resorts to a procedure of exposing a metal molten in advance within a retaining oven to a cooling means, thereby cooling this molten metal to the solid-liquid coexisting state formed of a solid phase and a liquid phase, and converting this solid-liquid composite into a metal slurry while retaining it in the range of semiliquid temperature within a retaining container.
- the method using this procedure is enabled to obtain an expected metal slurry without requiring use of such an expensive extruding device as is indispensable to the thixo-casting method because numerous crystal nuclei are precipitated at the stage at which the molten metal contacts the cooling means and these crystal nuclei are destined to grow into spheres within the retaining container.
- This method further, enables the casting aimed at to be fulfilled by effective utilization of the fluidity of the semisolid metal because it permits easy determination of the question whether or not the metal slurry formed in the retaining container has assumed the expected state of non-dendritic crystals.
- the control is all the more complicated because the metal slurry in each of the retaining containers requires accurate control of temperature till it is supplied to the metallic mold.
- the present inventors in the light of the actual state of things mentioned above, have proposed a method for casting a metal, which comprises a first production step for forming a metal slurry containing a solid phase by cooling a molten metal, a second production step for forming a solidified metal material by further cooling the metal slurry, and a step for heating the metal material till a semiliquid state and supplying the semiliquid metal material to a metallic mold.
- this method is enabled to obtain a metal slurry abounding in fluidity and containing non-dendritic crystals without requiring any complicated control and, by supplying this metal slurry to the metallic mold, further enabled to obtain a mass of metal.
- the press working proves advantageous in terms of cost because the productivity thereof is 20 - 100 times as high as that of die-casting or injection-molding. Since plates are easy of working, the desirability of materializing manufacture of a platelike metal material by effective utilization of thixotropy has been finding enthusiastic recognition.
- This invention conceived and perfected with a view to attaining the desire mentioned above, aims to provide a method for the production of a platelike metal material by such effective utilization of thixotropy as to permit manufacture of a product by press working and an apparatus for the production thereof.
- a method for the production of a platelike metal material comprising the steps of: providing molten metal in a melting tank (M1) in a liquid-phase temperature state: supplying the molten metal to at least one guide groove (22) of a cooling unit (21) provided with a circulating path for cooling fluid, said cooling unit being disposed so as to slant downwardly from the melting tank whereby there is formed a metal slurry having numerous crystal nuclei precipitated therein; supplying the metal slurry slurry to a storing tank (M2) to grow the numerous crystal nuclei into spherical crystals; discharging the metal slurry containing the spherical crystals from a nozzle (33) provided on a lower side of the storing tank; and cooling the discharged metal slurry and, at the same time, rolling the same to form a continuous, solidified, platelike metal material.
- the method may include cutting a continuous, solidified, platelike metal material into pieces of a stated length or a winding work for winding a continuous, solidified, platelike metal material into rolls of a stated diameter.
- an apparatus for the production of a platelike metal material comprising a melting tank (M1) for containing molten metal in a liquid-phase temperature state; a cooling unit (21) provided on a surface thereof with at least one guide groove (22) and having a circulating path (23) for cooling fluid, said cooling unit being disposed so as to slant downwardly from the melting tank and being suitable for cooling the molten metal in the at least one guide groove so as to form there from a metal slurry having numerous crystal nuclei precipitated therein; a storing tank (M2) provided with a material path for discharging stored metal slurry downwardly and disposed at a lower end of the cooling unit; a nozzle (33) disposed at a lower end of the material path; and roller means (37) for rolling the metal slurry discharged from the nozzle while cooling the same to form a continuous, solidified, platelike metal material.
- M1 melting tank
- a cooling unit (21) provided on a surface thereof with at least one guide groove (22) and having a circulating
- the apparatus may include a cutting mechanism for cutting a continuous, solidified, platelike metal material into pieces of a stated length or a winding mechanism for winding the continuous, solidified, platelike material formed into rolls of a stated diameter.
- Embodiments of the invention enable the numerous crystal nuclei precipitated in the metal slurry to attain further growth into spheres and, by subjecting the metal slurry in the ensuing state simultaneously to the treatments of cooling and rolling, makes it possible to render the product fit for press working and to exalt the productivity of the operation itself markedly.
- FIG. 1 schematically illustrates the construction of the apparatus for the production of a platelike metal material as one embodiment of this invention.
- reference numeral 11 denotes a melting tank for retaining a magnesium alloy represented by the AZ type or the AM type, for example, in a molten state or in a state of liquid phase temperature.
- This melting tank 11 is furnished around the periphery thereof with a heater 12.
- the melting tank 11 is provided in the lowermost part thereof with a tapping path 11 a bent roughly in the shape of a crank and used for discharging the stored molten magnesium alloy M1 downward.
- the tapping path 11 a is provided halfway the length thereof with a switch valve 13 that is composed of a valve plunger 13p so disposed as to produce a forward or backward motion to open or close the tapping path 11a and a valve cylinder 13c serving the purpose of moving the valve plunger 13p forward or backward.
- a cooling unit 21 is disposed as a first production means.
- This cooling unit 21, as illustrated in detail in Figures 2(a) and 2(b), is so constructed as to be furnished on the surface thereof with a guide groove 22 and in the interior thereof with a circulating path 23 for cooling water.
- a guide groove 22 is a guide groove 22 and in the interior thereof with a circulating path 23 for cooling water.
- Figure 2 is depicted as using one guide groove 22, it is permissible to use a plurality of such guide grooves.
- This cooling unit 21 is disposed as being slanted in such a state that the guide groove 22 is opposed to the lower end of the tapping path 11a.
- the cooling unit 21 is so disposed in a cover block 24 that this cover block 24 covers the cooling unit 12 while securing a stated intervening space between the opposed surfaces.
- the empty space on the upper surface of the cooling unit 21 communicates with the lower end of the tapping path 11a.
- the cover block 24 and a storing tank 32 that will be specifically described herein below are jointly provided with a guide block 25 through which they are interconnected.
- a second production means which is denoted by reference numeral 31 comprises the storing tank 32 furnished in the lowermost part thereof with a material path 32a for discharging a stored metal slurry M2 downward, a nozzle 33 disposed on the lower side of the storing tank 32 and furnished with a supply path 33p formed roughly in the shape of the letter L so as to communicate at the upper end thereof with the lower end of the material path 32a, a switch valve 34 for controlling the flow of the metal slurry M2 from the material path 32a to the supply path 33p, an auxiliary heater 35 disposed in the nozzle 33 and adapted to retain the metal slurry in the nozzle 33 at a stated temperature, width regulating guides 36L and 36R disposed on the left and right sides of the leading end of the nozzle 33 as illustrated in Figure 3 and adapted to regulate the width of a continuous, platelike metal material M3, a pair of coarse roller 37D and 37U adapted to cool and roll simultaneously the metal slurry M2 discharged from the nozzle 33, a pair of finishing
- the switch valve 34 comprises a valve plunger 34p adapted to producing a forward or backward motion to open or close the material path 32a and a valve cylinder 34c adapted to move the valve plunger 34p forward or backward.
- the cutting mechanism 39 comprises a cutter 39c disposed on the downstream side of the finishing rollers 38D and 38U and an end-detecting sensor 39s disposed on the downstream side of the cutter 39c as being separated by a stated length (the length of pieces obtained by cutting) from the cutter 39c and adapted to detect the end (leading end) of the continuous, platelike metal material M3.
- the coarse rollers 37D and 37U are so constructed as to directly contact and suddenly cool the metal slurry M2 by means of a built-in water-cooled cooling unit, for example.
- the leading end of the supply path 33p is diverged in the vertical direction as illustrated in Figure 4 so as to facilitate the emission of the metal slurry M2.
- the pair of coarse rollers 37D and 37U are adapted so as to be synchronously rotated by a drive mechanism omitted from illustration here, with the result that the coarse roller 37D will be rotated counterclockwise and the coarse roller 37U clockwise.
- the pair of finishing rollers 38D and 38U are adapted so as to be synchronously rotated by a drive mechanism omitted from illustration here, with the result that the finishing roller 38D will be rotated counterclockwise and the finishing roller 38U clockwise.
- the operation of the apparatus will be explained.
- the melting tank 11 is enabled to retain the molten magnesium alloy M1 and, at the same time, the cooling unit 21 is enabled to admit the flow of the cooling water.
- the apparatus is readied for operation by setting the coarse rollers 37D and 37U rotating at a stated speed and also setting the finishing roller 38D and 38U rotating at a stated speed.
- the cooling units in the coarse rollers 37D and 37U are made to allow flow of cooling water therethrough and the auxiliary heater 35 is connected to a power source.
- the tapping path 11a is opened and the molten magnesium alloy M1 stored in the melting tank 11 is supplied via the tapping path 11a to the cooling unit 21.
- the molten magnesium alloy M1 that has been supplied to the cooling unit 21 flows down the guide groove 22 along the inclination of the cooling unit 31 and is then put to temporary storage in the storing tank 32.
- the molten magnesium alloy M1 that flows down the cooling unit 21 is properly cooled by the cooling unit 21 and consequently transformed into the metal slurry M2 having numerous crystal nuclei precipitated therein.
- the crystal nuclei further gain in growth into spheres and eventually give rise to fine and uniform spherical crystals.
- the metal slurry M2 containing the spherical crystal nuclei and discharged through the supply path 33p as illustrated in Figure 4(b) is cooled by contacting the coarse rollers 37D and 37U currently in rotation, with the result that it will be continuously discharged in the form of a perfectly solidified plate and eventually enabled to form a continuous, platelike metal material M3 as illustrated in Figure 4(c).
- the continuous, platelike metal material M3 discharged through the supply path 33p is conveyed as being compressed by the width regulating guides 36L and 36R to a stated width and rolled by the coarse rollers 37D and 37U and subsequently given a finish rolling treatment by the finishing rollers 38D and 38U and advanced through the gap between the cutters 39c.
- the perfectly solidified continuous, platelike metal material M3 is formed by suddenly cooling the metal slurry M2 which still retains thixotropy sufficiently.
- the latent retention of this thixotropy can be easily confirmed by visual observation of the crystal structure contained in the continuous, platelike metal material M3.
- the cutter 39c When the end-detecting sensor 39s detects the leading end of the advancing continuous, platelike metal material M3, the cutter 39c is actuated to cut the continuous, platelike metal material M3 into pieces of a stated length.
- the cut pieces are conveyed as platelike metal materials M4 by means of a conveyor, for example.
- this invention is capable of producing platelike metal materials M4 by effectively utilizing thixotropy as described above, the platelike metal materials M4 are enabled by press working to give birth to required products with high productivity as compared with the die-casting or the injection-molding.
- Figure 6(a) is a photomicrograph of the platelike metal material produced by cooling the melt of magnesium alloy (AZ91D magnesium alloy) in the melting tank with the cooling unit into a metal slurry in the storing tank and bringing the metal slurry discharged from the nozzle into contact with the guide rollers.
- AZ91D magnesium alloy AZ91D magnesium alloy
- Figure 6(b) is a photomicrograph, for comparison with that of Figure 6(a), of the platelike metal material that has been heated again at 570°C, from which it is found that thixotropy emerges because liquid metal exists around the crystals.
- Figure 6(c) is a photomicrograph of a conventional metal material obtained by casting a melt of metal without use of the cooling unit of the present invention, from which it is found that emergence of thixotropy cannot be expected because the crystals have a non-dendritic structure.
- this invention is capable of producing platelike metal materials using aluminum, aluminum alloys, other metals and alloys thereof as the raw materials.
- Figure 5 shows the apparatus equipped with the winding mechanism in place of the cutting mechanism, in which the metal slurry M2 containing spherical crystal nuclei that is discharged from the nozzle 33 is brought into contact with the coarse rollers 37D and 37U for cooling, then rolled by the finishing rollers 38D and 38U and wound on a winding drum 40 in the form of the continuous, platelike metal material.
- the length of the continuous, platelike metal material which permits the formed roll on the winding drum 40 to acquire a stated diameter may be calculated with a calculating mechanism prior to the cutting work with the cutter 39c.
- the raw material (plate material) for the manufacture of finished products allows easy handling and also allows easy supply of the raw material to the site of manufacture.
- the raw material suitable for mass production can be handled and supplied.
- this invention is capable of producing platelike metal materials by effectively utilizing thioxtropy as described above, it is enabled by subjecting these platelike metal materials to the operation of press working to give rise to required products with high productivity as compared with die-casting or injection-molding.
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Description
- This invention relates to a method and apparatus for the production of a platelike metal material by effective utilization of the thixotropy inherent in a semiliquid/semisolid metal.
- The thixo-casting method (semiliquid casting method) and rheocasting method (semisolid casting method) have been known as casting methods utilizing the thixotropy inherent in a semiliquid/semisolid metal, namely the property of exhibiting small viscosity and excelling in fluidity.
- These casting methods invariably consist in casting a metal slurry in such a semiliquid/semisolid state formed of an interfused mixture of a liquid-phase metal and a solid-phase metal.
- The thixo-casting method is so adapted as to comprise the steps of heating a solid metal till formation of a metal slurry in the semiliquid state and supplying the formed metal slurry to a metallic mold.
- The rheocasting method is so adapted as to comprise the steps of provisionally melting a solid metal, cooling the resultant molten metal till formation of a metal slurry in the semisolid state containing granular crystals, and subsequently supplying the metal slurry to a metallic mold.
- Since these casting methods are capable of casting a metal having a high solid-phase ratio and exhibiting low viscosity, they are at an advantage in improving the metallic mold in filling capacity, thereby enhancing the yield of casting, enabling formation of a product of a large size, repressing occurrence of a shrinkage cavity, thereby adding to the mechanical strength of the product, and permitting a reduction in the wall thickness of the product.
- Further, they are capable of allaying the thermal load exerted on the metallic mold and, therefore, elongating the service life of the metallic mold.
- With the aim of effectively utilizing the thixotropy of a semiliquid metal and the fluidity of a semisolid metal respectively in the casting methods described above, it is necessary that the semiliquid/semisolid metal should contain non-dendritic crystals, preferably spherical crystals, as fine and uniform as permissible.
- When the solid metal is heated till formation of a semiliquid state and the molten metal is simply cooled till formation of a semisolid state, however, these metals nearly wholly take part in giving rise to dendritic crystals in the semiliquid/semisolid metal and rendering it impossible to obtain the thixotropy of the semiliquid metal and the fluidity of the semisolid metal fully satisfactorily.
- The thixo-molding method, therefore, generally resorts to a procedure of utilizing a screw-type extruding device popularly used in an injection molding machine and sequentially heating a given solid metal within the barrel of the extruding device while exerting a shearing force thereon till conversion of the solid metal into a metal slurry in a semiliquid state.
- Since the screw-type extruding device is complicated in structure and, accordingly, is expensive, however, the cost for application thereof to the casting equipment is very enormous.
- Since the metal slurry formed within the barrel of the extruding device is fated to be supplied in its unmodified form to the metallic mold, it cannot be confirmed at all whether or not the crystals formed have assumed the state of non-dendritic crystals.
- Further, since the solid metal to be used for supply to the barrel must be prepared in the form of chips, the cost of the raw material is very high.
- Meanwhile, the rheocasting method, as disclosed in
JP-A HEI 10-34307 - The method using this procedure is enabled to obtain an expected metal slurry without requiring use of such an expensive extruding device as is indispensable to the thixo-casting method because numerous crystal nuclei are precipitated at the stage at which the molten metal contacts the cooling means and these crystal nuclei are destined to grow into spheres within the retaining container.
- Moreover, since a mass of metal may be supplied in its unmodified form to the retaining oven, the cost of the raw material can be restrained from being increased.
- This method, further, enables the casting aimed at to be fulfilled by effective utilization of the fluidity of the semisolid metal because it permits easy determination of the question whether or not the metal slurry formed in the retaining container has assumed the expected state of non-dendritic crystals.
- In the rheocasting method, however, the actual construction of a system for mass production makes it necessary to interpose numerous retaining containers between the cooling means serving the purpose of cooling the molten metal and the metallic mold serving as a receptacle for storing the metal slurry being supplied thereto and, at the same time, synchronize the step of causing the molten metal to contact the cooling means with the step of supplying the metal slurry to the metallic mold through such numerous retaining containers. The system, therefore, necessitates extremely complicated control.
- The control is all the more complicated because the metal slurry in each of the retaining containers requires accurate control of temperature till it is supplied to the metallic mold.
- The present inventors, in the light of the actual state of things mentioned above, have proposed a method for casting a metal, which comprises a first production step for forming a metal slurry containing a solid phase by cooling a molten metal, a second production step for forming a solidified metal material by further cooling the metal slurry, and a step for heating the metal material till a semiliquid state and supplying the semiliquid metal material to a metallic mold.
- As a result, this method is enabled to obtain a metal slurry abounding in fluidity and containing non-dendritic crystals without requiring any complicated control and, by supplying this metal slurry to the metallic mold, further enabled to obtain a mass of metal.
- Incidentally, the press working proves advantageous in terms of cost because the productivity thereof is 20 - 100 times as high as that of die-casting or injection-molding. Since plates are easy of working, the desirability of materializing manufacture of a platelike metal material by effective utilization of thixotropy has been finding enthusiastic recognition.
- This invention, conceived and perfected with a view to attaining the desire mentioned above, aims to provide a method for the production of a platelike metal material by such effective utilization of thixotropy as to permit manufacture of a product by press working and an apparatus for the production thereof.
- According to one aspect of the present invention there is provided a method for the production of a platelike metal material, comprising the steps of: providing molten metal in a melting tank (M1) in a liquid-phase temperature state: supplying the molten metal to at least one guide groove (22) of a cooling unit (21) provided with a circulating path for cooling fluid, said cooling unit being disposed so as to slant downwardly from the melting tank whereby there is formed a metal slurry having numerous crystal nuclei precipitated therein; supplying the metal slurry slurry to a storing tank (M2) to grow the numerous crystal nuclei into spherical crystals; discharging the metal slurry containing the spherical crystals from a nozzle (33) provided on a lower side of the storing tank; and cooling the discharged metal slurry and, at the same time, rolling the same to form a continuous, solidified, platelike metal material.
- The method may include cutting a continuous, solidified, platelike metal material into pieces of a stated length or a winding work for winding a continuous, solidified, platelike metal material into rolls of a stated diameter.
- According to another aspect of the present invention there is provided an apparatus for the production of a platelike metal material, comprising a melting tank (M1) for containing molten metal in a liquid-phase temperature state; a cooling unit (21) provided on a surface thereof with at least one guide groove (22) and having a circulating path (23) for cooling fluid, said cooling unit being disposed so as to slant downwardly from the melting tank and being suitable for cooling the molten metal in the at least one guide groove so as to form there from a metal slurry having numerous crystal nuclei precipitated therein; a storing tank (M2) provided with a material path for discharging stored metal slurry downwardly and disposed at a lower end of the cooling unit; a nozzle (33) disposed at a lower end of the material path; and roller means (37) for rolling the metal slurry discharged from the nozzle while cooling the same to form a continuous, solidified, platelike metal material.
- The apparatus may include a cutting mechanism for cutting a continuous, solidified, platelike metal material into pieces of a stated length or a winding mechanism for winding the continuous, solidified, platelike material formed into rolls of a stated diameter.
- Embodiments of the invention enable the numerous crystal nuclei precipitated in the metal slurry to attain further growth into spheres and, by subjecting the metal slurry in the ensuing state simultaneously to the treatments of cooling and rolling, makes it possible to render the product fit for press working and to exalt the productivity of the operation itself markedly.
- The other objects and characteristic features of this invention will become apparent from the detailed description to be given herein below with reference to the annexed drawings, in which:-
- Figure 1 is an explanatory diagram schematically depicting the construction of an apparatus for the production of a platelike metal material as one embodiment of this invention,
- Figure 2(a) is a schematic longitudinal cross section of a cooling unit for forming a metal slurry in the apparatus of Figure 1,
- Figure 2(b) is a section of the cooling unit of Figure 2(a),
- Figure 3 is a partially omitted cutaway plan view of the leading end portion of a nozzle in the apparatus of Figure 1,
- Figure 4(a) is an explanatory diagram depicting the state in which the metal slurry flows in the direction of the opening at the leading end of the nozzle in the apparatus of Figure 1,
- Figure 4(b) is an explanatory diagram depicting the state in which the metal slurry shown in Figure 4(a) is on the verge of emanating from the opening of the nozzle,
- Figure 4(c) is an explanatory diagram depicting the operation of cooling and rolling the metal slurry shown in Figure 4(b),
- Figure 5 is an explanatory diagram schematically depicting the configuration of a winding mechanism used in the apparatus of Figure 1,
- Figure 6(a) is a photomicrograph showing the platelike metal material produced according to the method of the present invention,
- Figure 6(b) is a photomicrograph showing the platelike metal material of Figure 6(a) that has been heated again at a solid-liquid coexisting temperature and then quenched in water,
- Figure 6(c) is a photomicrograph showing a casting ingot produced by a conventional method.
- Figure 1 schematically illustrates the construction of the apparatus for the production of a platelike metal material as one embodiment of this invention. In this diagram,
reference numeral 11 denotes a melting tank for retaining a magnesium alloy represented by the AZ type or the AM type, for example, in a molten state or in a state of liquid phase temperature. Thismelting tank 11 is furnished around the periphery thereof with aheater 12. - The
melting tank 11 is provided in the lowermost part thereof with a tapping path 11 a bent roughly in the shape of a crank and used for discharging the stored molten magnesium alloy M1 downward. - The tapping path 11 a is provided halfway the length thereof with a
switch valve 13 that is composed of a valve plunger 13p so disposed as to produce a forward or backward motion to open or close the tapping path 11a and avalve cylinder 13c serving the purpose of moving the valve plunger 13p forward or backward. - Below the
melting tank 11, acooling unit 21 is disposed as a first production means. Thiscooling unit 21, as illustrated in detail in Figures 2(a) and 2(b), is so constructed as to be furnished on the surface thereof with aguide groove 22 and in the interior thereof with a circulatingpath 23 for cooling water. Though the example of Figure 2 is depicted as using oneguide groove 22, it is permissible to use a plurality of such guide grooves. - This
cooling unit 21 is disposed as being slanted in such a state that theguide groove 22 is opposed to the lower end of the tapping path 11a. - The
cooling unit 21 is so disposed in acover block 24 that thiscover block 24 covers thecooling unit 12 while securing a stated intervening space between the opposed surfaces. The empty space on the upper surface of thecooling unit 21 communicates with the lower end of the tapping path 11a. - The
cover block 24 and astoring tank 32 that will be specifically described herein below are jointly provided with aguide block 25 through which they are interconnected. - A second production means which is denoted by
reference numeral 31 comprises thestoring tank 32 furnished in the lowermost part thereof with a material path 32a for discharging a stored metal slurry M2 downward, anozzle 33 disposed on the lower side of thestoring tank 32 and furnished with asupply path 33p formed roughly in the shape of the letter L so as to communicate at the upper end thereof with the lower end of the material path 32a, aswitch valve 34 for controlling the flow of the metal slurry M2 from the material path 32a to thesupply path 33p, anauxiliary heater 35 disposed in thenozzle 33 and adapted to retain the metal slurry in thenozzle 33 at a stated temperature,width regulating guides nozzle 33 as illustrated in Figure 3 and adapted to regulate the width of a continuous, platelike metal material M3, a pair ofcoarse roller nozzle 33, a pair offinishing rollers coarse rollers cutting mechanism 39 for cutting the continuous, platelike metal material M3 discharged through the gap between thefinishing rollers - The
switch valve 34 comprises a valve plunger 34p adapted to producing a forward or backward motion to open or close the material path 32a and a valve cylinder 34c adapted to move the valve plunger 34p forward or backward. - The
cutting mechanism 39 comprises acutter 39c disposed on the downstream side of thefinishing rollers sensor 39s disposed on the downstream side of thecutter 39c as being separated by a stated length (the length of pieces obtained by cutting) from thecutter 39c and adapted to detect the end (leading end) of the continuous, platelike metal material M3. - The
coarse rollers - Incidentally, the leading end of the
supply path 33p is diverged in the vertical direction as illustrated in Figure 4 so as to facilitate the emission of the metal slurry M2. - The pair of
coarse rollers coarse roller 37D will be rotated counterclockwise and thecoarse roller 37U clockwise. - Then, the pair of
finishing rollers finishing roller 38D will be rotated counterclockwise and thefinishing roller 38U clockwise. - Now, the operation of the apparatus will be explained. First, by introducing a mass of a magnesium alloy into the
melting tank 11 and actuating theheater 12, themelting tank 11 is enabled to retain the molten magnesium alloy M1 and, at the same time, thecooling unit 21 is enabled to admit the flow of the cooling water. Then, the apparatus is readied for operation by setting thecoarse rollers roller - In this case, the cooling units in the
coarse rollers auxiliary heater 35 is connected to a power source. - When the
valve cylinder 13c is actuated from the reset state to impart a backward motion to the valve plunger 13p, the tapping path 11a is opened and the molten magnesium alloy M1 stored in themelting tank 11 is supplied via the tapping path 11a to thecooling unit 21. - The molten magnesium alloy M1 that has been supplied to the
cooling unit 21 flows down theguide groove 22 along the inclination of the coolingunit 31 and is then put to temporary storage in thestoring tank 32. - The molten magnesium alloy M1 that flows down the cooling
unit 21 is properly cooled by the coolingunit 21 and consequently transformed into the metal slurry M2 having numerous crystal nuclei precipitated therein. In thestoring tank 32, the crystal nuclei further gain in growth into spheres and eventually give rise to fine and uniform spherical crystals. - Then, by actuating the
valve cylinder 34 so as to impart a backward motion to the valve plunger 34p and consequently opening the material path 32a, the metal slurry M2 which has been stored temporarily in thestoring tank 32 is enabled to be continuously discharged through thesupply path 33p of thenozzle 33 to the ambience as illustrated in Figure 4(a). - The metal slurry M2, while passing through the
supply path 33p, is retained at a stated temperature by theauxiliary heater 35. - Then, the metal slurry M2 containing the spherical crystal nuclei and discharged through the
supply path 33p as illustrated in Figure 4(b) is cooled by contacting thecoarse rollers - Thus, the continuous, platelike metal material M3 discharged through the
supply path 33p is conveyed as being compressed by the width regulating guides 36L and 36R to a stated width and rolled by thecoarse rollers rollers cutters 39c. - Incidentally, the perfectly solidified continuous, platelike metal material M3 is formed by suddenly cooling the metal slurry M2 which still retains thixotropy sufficiently. The latent retention of this thixotropy can be easily confirmed by visual observation of the crystal structure contained in the continuous, platelike metal material M3.
- When the end-detecting
sensor 39s detects the leading end of the advancing continuous, platelike metal material M3, thecutter 39c is actuated to cut the continuous, platelike metal material M3 into pieces of a stated length. The cut pieces are conveyed as platelike metal materials M4 by means of a conveyor, for example. - While the continuous, platelike metal material M3 is being cut into platelike metal materials M4, this continuous, platelike metal material M3 droops and absorbs excess length. When the
cutter 39c is opened, the continuous, platelike metal material M3 advances with the elasticity of its own. - Thereafter, the continuous, platelike metal material M3 is successively cut likewise to give rise to platelike metal materials M4.
- Since this invention is capable of producing platelike metal materials M4 by effectively utilizing thixotropy as described above, the platelike metal materials M4 are enabled by press working to give birth to required products with high productivity as compared with the die-casting or the injection-molding.
- Figure 6(a) is a photomicrograph of the platelike metal material produced by cooling the melt of magnesium alloy (AZ91D magnesium alloy) in the melting tank with the cooling unit into a metal slurry in the storing tank and bringing the metal slurry discharged from the nozzle into contact with the guide rollers.
- It is found from the photomicrograph that numerous crystal nuclei grown to a large size are crystallized in the platelike metal material thus produced.
- Figure 6(b) is a photomicrograph, for comparison with that of Figure 6(a), of the platelike metal material that has been heated again at 570°C, from which it is found that thixotropy emerges because liquid metal exists around the crystals.
- Figure 6(c) is a photomicrograph of a conventional metal material obtained by casting a melt of metal without use of the cooling unit of the present invention, from which it is found that emergence of thixotropy cannot be expected because the crystals have a non-dendritic structure.
- Though the embodiment described above has illustrated the production of platelike metal materials from a magnesium alloy as the raw material, this invention is capable of producing platelike metal materials using aluminum, aluminum alloys, other metals and alloys thereof as the raw materials.
- In Figure 1, the example of furnishing the apparatus with the cutting mechanism (cutting step) for successively cutting the continuous, platelike metal material to produce platelike metal materials has been cited by way of illustration. Since the products of spherical crystals show an increase in strength by about 15% over the products of dendritic crystals, the necessity for furnishing the apparatus with the cutting mechanism may be obviated by providing a winding mechanism (winding step) for winding the continuous, platelike metal material directly around itself or indirectly around a core of a stated diameter. Figure 5 shows the apparatus equipped with the winding mechanism in place of the cutting mechanism, in which the metal slurry M2 containing spherical crystal nuclei that is discharged from the
nozzle 33 is brought into contact with thecoarse rollers rollers - Incidentally, when the apparatus is furnished with the winding mechanism (winding step), the length of the continuous, platelike metal material which permits the formed roll on the winding drum 40 to acquire a stated diameter may be calculated with a calculating mechanism prior to the cutting work with the
cutter 39c. - When the continuous, platelike metal material that has been finish-rolled by the finishing
rollers - When the continuous, platelike metal material is wound in rolls, the raw material (plate material) for the manufacture of finished products allows easy handling and also allows easy supply of the raw material to the site of manufacture. Thus, the raw material suitable for mass production can be handled and supplied.
- Since this invention is capable of producing platelike metal materials by effectively utilizing thioxtropy as described above, it is enabled by subjecting these platelike metal materials to the operation of press working to give rise to required products with high productivity as compared with die-casting or injection-molding.
Claims (6)
- A method for the production of a platelike metal material, comprising the steps of:providing molten metal in a melting tank (M1) in a liquid-phase temperature state:supplying the molten metal to at least one guide groove (22) of a cooling unit (21) provided with a circulating path (23) for cooling fluid, said cooling unit being disposed so as to slant downwardly from the melting tank whereby there is formed a metal slurry having numerous crystal nuclei precipitated therein;supplying the metal slurry slurry to a storing tank (M2) to grow the numerous crystal nuclei into spherical crystals;discharging the metal slurry containing the spherical crystals from a nozzle (33) provided on a lower side of the storing tank; and
cooling the discharged metal slurry and, at the same time, rolling the same to form a continuous, solidified, platelike metal material. - A method according to claim 1, including cutting the continuous, solidified, platelike metal material into pieces (M4) of a stated length.
- A method according to claim 1, including winding the continuous, solidified, platelike metal material into rolls of a stated diameter.
- An apparatus for the production of a platelike metal material, comprising
a melting tank (M1) for containing molten metal in a liquid-phase temperature state:a cooling unit (21) provided on a surface thereof with at least one guide groove (22) and having a circulating path (23) for cooling fluid, said cooling unit being disposed so as to slant downwardly from the melting tank and being suitable for cooling the molten metal in the at least one guide groove so as to form therefrom a metal slurry having numerous crystal nuclei precipitated therein;a storing tank (M2) provided with a material path for discharging stored metal slurry downwardly and disposed at a lower end of the cooling unit;a nozzle (33) disposed at a lower end of the material path; androller means (37) for rolling the metal slurry discharged from the nozzle while cooling the same to form a continuous, solidified, platelike metal material. - An apparatus according to claim 4, wherein including a cutting means (39) for cutting the continuous, solidified, platelike metal material into pieces (M4) of a stated length.
- An apparatus according to claim 4, including a winding mechanism (40) for winding the continuous, solidified, platelike metal material into rolls of a stated diameter.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2001088378 | 2001-03-26 | ||
JP2001088378A JP3867769B2 (en) | 2001-03-26 | 2001-03-26 | Method and apparatus for manufacturing plate metal material |
Publications (2)
Publication Number | Publication Date |
---|---|
EP1245311A1 EP1245311A1 (en) | 2002-10-02 |
EP1245311B1 true EP1245311B1 (en) | 2007-07-18 |
Family
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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EP02252063A Expired - Lifetime EP1245311B1 (en) | 2001-03-26 | 2002-03-22 | Method and apparatus for production of platelike metal material |
Country Status (5)
Country | Link |
---|---|
US (1) | US20020134471A1 (en) |
EP (1) | EP1245311B1 (en) |
JP (1) | JP3867769B2 (en) |
CA (1) | CA2379065C (en) |
DE (1) | DE60221175T2 (en) |
Families Citing this family (12)
Publication number | Priority date | Publication date | Assignee | Title |
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JP4661857B2 (en) * | 2001-04-09 | 2011-03-30 | 住友電気工業株式会社 | Magnesium alloy material and method for producing the same |
JP4082217B2 (en) * | 2001-04-09 | 2008-04-30 | 住友電気工業株式会社 | Magnesium alloy material and method for producing the same |
AU2003294225A1 (en) * | 2002-09-23 | 2004-04-23 | Worcester Polytechnic Institute | Method for making an alloy and alloy |
AU2003900971A0 (en) * | 2003-02-28 | 2003-03-13 | Commonwealth Scientific And Industrial Research Organisation | Magnesium alloy sheet and its production |
AU2003260197B2 (en) * | 2003-02-28 | 2007-05-17 | Commonwealth Scientific And Industrial Research Organisation | Magnesium alloy sheet and its production |
JP3503898B1 (en) * | 2003-03-07 | 2004-03-08 | 権田金属工業株式会社 | Method and apparatus for manufacturing magnesium metal sheet |
AU2003255156A1 (en) * | 2003-07-24 | 2005-02-14 | Sumitomo Metal Industries, Ltd. | Process for producing magnesium alloy thin sheet and apparatus therefor |
KR101193064B1 (en) * | 2004-12-24 | 2012-10-22 | 재단법인 포항산업과학연구원 | System of casting operation in manufacturing Mg strip with horizontal twin roll strip casting apparatus |
JP4697657B2 (en) * | 2005-03-22 | 2011-06-08 | 住友電気工業株式会社 | Manufacturing method of magnesium long material |
CN100366351C (en) * | 2006-01-26 | 2008-02-06 | 鞍山科技大学 | On line oil bath thermal treating twin roll casting rolling method and apparatus |
JP6524689B2 (en) * | 2015-02-13 | 2019-06-05 | 株式会社Ihi | Continuous casting equipment |
CN111992810A (en) * | 2020-08-17 | 2020-11-27 | 浙江灿根智能科技有限公司 | Copper pipe traction device capable of automatically adjusting traction force |
Family Cites Families (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR2578768B1 (en) * | 1985-03-15 | 1988-05-06 | C3F Comp Franc Forges Fond | CONTINUOUS CASTING ROLLER BRAKES |
JPH01138044A (en) * | 1987-11-25 | 1989-05-30 | Ishikawajima Harima Heavy Ind Co Ltd | Apparatus for producing semi-solidified slurry |
JP2869066B2 (en) * | 1988-01-07 | 1999-03-10 | 石川島播磨重工業株式会社 | Continuous sheet manufacturing equipment |
JPH01309760A (en) * | 1988-06-08 | 1989-12-14 | Furukawa Electric Co Ltd:The | Continuous casting method |
US5144998A (en) * | 1990-09-11 | 1992-09-08 | Rheo-Technology Ltd. | Process for the production of semi-solidified metal composition |
US5452827A (en) * | 1993-07-13 | 1995-09-26 | Eckert; C. Edward | Nozzle for continuous caster |
CA2517447C (en) * | 1994-07-19 | 2007-05-29 | Alcan International Limited | Process and apparatus for casting metal strip and injector used therefor |
CN1265915C (en) * | 2000-08-11 | 2006-07-26 | 布鲁内尔大学 | Method and apparatus for making metal alloy castings |
-
2001
- 2001-03-26 JP JP2001088378A patent/JP3867769B2/en not_active Expired - Fee Related
-
2002
- 2002-03-22 EP EP02252063A patent/EP1245311B1/en not_active Expired - Lifetime
- 2002-03-22 DE DE60221175T patent/DE60221175T2/en not_active Expired - Lifetime
- 2002-03-25 US US10/103,794 patent/US20020134471A1/en not_active Abandoned
- 2002-03-26 CA CA2379065A patent/CA2379065C/en not_active Expired - Fee Related
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Also Published As
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US20020134471A1 (en) | 2002-09-26 |
CA2379065C (en) | 2010-12-07 |
EP1245311A1 (en) | 2002-10-02 |
JP2002283007A (en) | 2002-10-02 |
JP3867769B2 (en) | 2007-01-10 |
DE60221175D1 (en) | 2007-08-30 |
CA2379065A1 (en) | 2002-09-26 |
DE60221175T2 (en) | 2008-05-21 |
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